7800 Series RM7888A Relay Module

Transcription

1 7800 Series RM7888A Relay Module FEATURES PRODUCT DATA APPLICATION The Honeywell RM7888A Relay Module is a microprocessor based, integrated burner control for industrial process semiautomatically fired gas, oil, coal, or combination fuels for single and multiple burner industrial applications. The RM7888A requires a Relay Module, Subbase and Amplifier for operation. Options include Keyboard Display Module, DATA CONTROLBUS MODULE, Modbus Module, and Remote Display Mounting. The RM7888 intended use is in conjunction with a master system control. The master system control determines the purge timing and confirms air supply and air flow. The RM7888A is programmed to provide a level of safety, functional capability and features beyond the capability of conventional controls. The basic functions of the RM7888 include automatic burner startup sequencing, five user selectable operating (run) sequences, four line voltage sequence control inputs (commonly controlled with a Programmable Logic Controller [PLC)], flame supervision, system status indication, system or self-diagnostics and troubleshooting. Contents Specifications... 2 Ordering Information... 2 Principal Technical Features... 8 Saftey Provisons... 9 Installation Wiring Assembly Operation Static Checkout Checkout Troubleshooting Safety features: Closed loop logic test. Dynamic input check. Dynamic safety relay test. Dynamic self-check logic. Expanded safe-start check. Internal hardware status monitoring. Tamper resistant timing and logic. Access for external electrical voltage checks. Application flexibility. Communication interface capability using Modbus. First-out annunciation and system diagnostics are provided by the optional Keyboard Display Module. Five sequence information LEDs. Interchangeable plug-in flame amplifiers. Local or remote annunciation of RM7888A operation and fault information. Dependable, long-term operation provided by microcomputer technology. Nonvolatile memory for retaining history files and sequencing status after loss of power. Remote reset capability (optional). Burner controller data: Sequence status. Sequence time. Hold status. Lockout/alarm status. Flame signal strength. Expanded annunciator status. Total hours of operation. Total cycles of operation. Fault history of six most recent faults: Cycles of operation at the time of the fault. Expanded annunciator data at the time of the fault. Fault message and code. Hours of operation at the time of the fault. Sequence status at the time of the fault. Sequence time at the time of the fault. SIL3 Capable

2 Diagnostic information: Device type. Flame amplifier type. Flame failure response time. Manufacturing code. On/Off status of all line voltage digital inputs. Software revision and version of RM7888A via S7800 Keyboard Display Module. Status of configuration jumpers. SPECIFICATIONS Electrical Ratings (see Table 1): Voltage and Frequency: 120 Vac (+10/-15%), 50/60 Hz (±10%). Keyboard Display Module: 13.0 Vdc peak full wave rectified (+20/-15%). Power Dissipation: RM7888A: 10W maximum. Display Module: 3W maximum. Maximum Total Connected Load: 2000 VA. Fusing: Total Connected Load: 20A maximum, type FRN or equivalent. Environmental Ratings: Ambient Temperature: Operating: -40 F to +140 F [-40 C to +60 C]. Storage: -40 F to F [-40 C to +66 C]. Humidity: 85% relative humidity continuous, noncondensing. Vibration: 0.5G environment. SIL 3 Capable: SIL 3 Capable in a properly designed Safety Instrumented System using Dynamic self check or amplicheck amplifiers with the appropriate flame detector. See form number for Certificate Agreement. Dimensions: See Fig. 1 Weight: RM7888A: 1 pound, 10 ounces [737 grams], unpacked. Keyboard Display Module: 4 ounces [113 grams], unpacked. Approval Bodies: Underwriters Laboratories Inc. component recognized. Canadian Standards Association certified. Factory Mutual approved. BURNER CONTROL 5 (127) MAIN ALARM 1 1 RESET 5 (127) 5-1/4 (133) 6-3/32 (155) 1 REMOVE ONLY FOR TERMINAL TEST ACCESS. MODULE WITH SUBBASE M15518B Fig. 1. Mounting dimensions of the RM7888A Relay Module and Q7800A Subbase in in. [mm]. The RM7888 is a component of a larger overall combustion safety system for industrial-burner applications. Due to the custom design nature inherent in industrial-burner control systems, the system designer/ integrator has responsibility for the overall combustion system safety and system approval. Separate appliance or site approval may also be required. The RM7888 serves as a system component that provides control and flame safety monitoring for an individual burner. ORDERING INFORMATION When purchasing replacement and modernization products from your TRADELINE wholesaler or distributor, refer to the TRADELINE Catalog or price sheets for complete ordering number. If you have additional questions, need further information, or would like to comment on our products or services, please write or phone: 1. Your local Honeywell Environmental and Combustion Controls Sales Office (check white pages of your phone directory). 2. Honeywell Customer Care 1885 Douglas Drive North Minneapolis, Minnesota or International Sales and Service Offices in all principal cities of the world. Manufacturing in Belgium, Canada, China, Czech Republic, Germany, Hungary, Italy, Mexico, Netherlands, United Kingdom, and United States

3 Mounting: Q7800A1005 for panel mount or Q7800B1003 or B1011 for wall or burner mount. Accessories: Required for Operation: Plug-in Flame Signal Amplifier (see Table 4). Optional: Modbus Module part number S7810M1003 DATA CONTROLBUS MODULE part number S7810A1009. Flame Simulators: Rectifying part number A. Ultraviolet part number Keyboard Display Module part number S7800A1001. Remote Reset Module part number S7820A1007. Remote Display Mounting Brackets part numbers , B, B. Extension Cable Assembly 60 inch part number A. 120 inch part number C. Tester part number A7800A1010. Table 1. Terminal Ratings. Terminal Number Description Ratings G Flame Sensor Ground 1 60 to 220 Vac, current limited. Earth G Earth Ground 1 L2(N) Line Voltage Common 3 Alarm 120 Vac, 1A pilot duty. 4 Line Voltage Supply (L1) 120 Vac (+10/-15%), 50/60 Hz (±10%) 2 5 Air Valve 120 Vac, 9.8A FL, 58.8A LR (inrush). 6 Special Function Vac, 1 ma. 7 Limits Complete 120 Vac, 9A. 8 Pilot Valve 3 9 Main Fuel Valve 3 10 Ignition 3 F(11) Flame Sensor 60 to 220 Vac, current limited. 12(B) Firing Rate High Fire 120 Vac, 75 VA Pilot Duty. 13(R) Firing Rate Common 120 Vac, 75 VA Pilot Duty. 14(W) Firing Rate Low Fire 120 Vac, 75 VA Pilot Duty. 15 Firing Rate Modulate 120 Vac, 75 VA Pilot Duty. 16 Unused 17 Special Function Vac, 1 ma. Fire Input 120 Vac, 1 ma. 19 Special Function Vac, 1 ma. 20 Special Function Vac, 1 ma. 21 Flame Proven 120 Vac, 2A pilot duty. 22 Shutter 120 Vac, 0.5A. 1 The RM7888 must have an earth ground providing a connection between the subbase and the control panel or the burner. The earth ground wire must be capable of conducting the current to blow the 15A fast blow fuse (or breaker) in event of an internal short circuit. The RM7888 needs a low impedance ground connection to the equipment frame which, in turn, needs a low impedance connection to earth ground. For a ground path to be low impedance at RF frequencies, the connection must be made with minimum length conductors having maximum surface areas. Wide straps or brackets are preferred rather than leadwires. Be careful to make sure that mechanically tightened joints along the ground path, such as pipe or conduit threads or surfaces held together with fasteners, are free of nonconductive coatings and are protected against mating surface corrosion VA maximum connected load to RM7888A Assembly. 3 See Table 2 and 3 for load combinations. IMPORTANT A Flame Detection System that must be ordered separately is required for operation. To select your Plugin Flame Signal Amplifier and applicable Flame Detector, see Table

4 a Jumper Terminals 8 to 9 for direct spark ignition. Table 2. Combinations for Terminals 8, 9, and 10. Pilot Fuel 8 Main 9 Ignition 10 C F No Load B F No Load F F A No Load F A D F a A D D A No Load D a A Table 3. Composition of Each Combination. A B C D F 4.5A ignition 50 VA Pilot Duty plus 4.5A ignition 180 VA Ignition plus Motor Valves with: 660 VA inrush, 360 VA open, 250 VA hold. 2A Pilot Duty 65 VA Pilot Duty plus motor valves with: 3850 VA inrush, 700 VA open, 250 VA hold. Table 4. Flame Detection Systems (FIGS. 2 8). Plug-In Flame Signal Amplifiers Applicable Flame Detectors Type Color Self-Checking Model Flame Failure Response Time (sec) a Fuel Type Models Rectification Green No R7847A e 0.8 or 3 Gas Rectifying Flame Rod Holders h No R7847A e 3 Gas, oil, coal Ultraviolet (Purple Peeper) Dynamic Amplicheck R7847B c,e 0.8 or 3 Gas Rectifying Flame Rod Holders h Dynamic Amplicheck Dynamic Self-check R7847B c,e 3 Gas, oil, coal Ultraviolet (Purple Peeper) R7847C g 3 Gas, oil, coal Ultraviolet (Purple Peeper) C7004, C7007, C7011 Complete Assemblies: C7008, C7009, Q179 C7012A,C C7004, C7007, C7011, Complete Assemblies: C7008, C7009, Q179 C7012A, C C7012E, F Infrared Red/White No R7852A 3 Gas, oil, coal Infrared C7915 Dynamic R7852B 3 Gas, oil, coal Infrared C7915 Amplicheck

5 Table 4. Flame Detection Systems (FIGS. 2 8). (Continued) Plug-In Flame Signal Amplifiers Applicable Flame Detectors Type Color Self-Checking Model Ultraviolet Purple No R7849A 0.8 or 3 Gas, oil Ultraviolet (Minipeeper) Blue Dynamic Amplicheck Dynamic Self-Check Dynamic Self-Check Optical White Dynamic Amplicheck Dynamic Self-Check Flame Failure Response Time (sec) a Fuel Type Models R7849B d 0.8 or 3 Gas, oil Ultraviolet (Minipeeper) R7861A b 0.8 or 3 Gas, oil, coal Ultraviolet C7061 R Gas, oil, coal Ultraviolet (Adjustable sensitivity) R7851B 0.8 or 3 Gas, oil, coal Optical (UV, Visible Light) R7851C b 3 Gas, oil, coal Optical (UV only) C7027, C7035, C7044 d C7027, C7035, C7044 d C7076 C7927, C7962 C7961 a Flame Failure Response Time (FFRT) depends on selection of amplifier. b Circuitry tests all electronic components in flame detection system (amplifier and detector) 12 times a minute during burner operation and shuts down burner if detection system fails. c Circuitry tests flame signal amplifier 12 times a minute during burner operation and shuts down burner if amplifier fails. d Use C7027, C7035 and C7044 Flame Detectors only on burners that cycle on-off at least once every twenty-four hours. Use C7061A Ultraviolet Detector with R7861A Amplifier or C7076A Flame Detector with R7886A Amplifier as ultraviolet flame detection system for appliances with burners that remain on continuously for twenty-four hours or longer. e R7847A,B Amplifiers with 0.8 second FFRT should NOT be used with C7012A,C Solid State Ultraviolet Detectors. g R7847C Series 4 or greater, check flame detector system when flame reaches 1.5 Vdc or at 4.5 seconds, whichever occurs first. R7847C Series 4 or greater, pulse the shutter when signal of 1.5 Vdc is sensed. Display readings of 0.7 to 2.4 Vdc are common. h Order flame rod separately; see flame detector Instructions for holder. IGNITION ELECTRODE (Q179C ONLY) ROD CERAMIC INSULATORS 1 (25) 1-21/32 (42) 1-13/32 (36) TARGET 3/8 (10) 3-1/8 (79) 1-1/16 (27) 1/2 (13) BRACKET 25/32 (20) 25/32 (20) 2-25/32 (62) 3/32 (2) 17/32 (14) 11/16 (18) THREADED MOUNTING HOLES (2) (10-32 UNF) M1983B Fig. 2. Rectification detectors

6 7-7/32 (183) MOUNTING FLANGE 3/4-14 NPT 3-3/4 (95) 5-1/8 (130) 3-7/16 (87) 1/2-14 NPSM LEADWIRES FACEPLATE C7012A,C,E,F, C /4 (133) M1962D Fig. 3. Rectification detectors. CELL MOUNT 2-3/4 (70) HEAT BLOCK 1-5/8 (41) 1-1/16 (27) 1-1/4 (32) 1-1/4 (32) BUSHING WITH MAGNIFYING LENS APERTURE 3/4-14 NPSM COLLAR, 3/4-14 NPSM INTERNAL THREADS C7915 3/4-14 NPSM INTERNAL THREADS M1982C Fig. 4. Infrared detector. 4 (102) 8 FOOT (2.44 METER) LEADWIRES (2) 3-1/2 (89) /16 (27) 1 2 COLLAR WITH 1/2-14 NPSM INTERNAL THREADS C7027A1064 HAS 24 FOOT (7.32 METER) LEADWIRES. C7027A1114 HAS 44 IN. (1.118 M) LEADWIRES WITH 22 IN. (558 MM) FLEXIBLE CONDUIT. MODELS AVAILABLE WITH SPUD CONNECTOR (1/2-14 NPSM INTERNAL THREADS) INSTEAD OF CLAMP TYPE CONNECTOR. Fig. 5. Ultraviolet detectors (minipeepers). M1943G 4-1/8 (105) COLLAR WITH /2 NPSM INTERNAL 1 THREADS 2 (51) 1-3/16 (30) 1/2-14 NPSM 2 INTERNAL THREADS 31/32 1-1/2 (25) (38) 2-5/8 (67) INSERTION DEPTH 6 FOOT [1.83 METER] LEADWIRES (2) 3 1 DIN APPROVED C7035A1064 HAS 1-11 BSP.P1 INTERNAL MOUNTING THREADS. 2 3 DIN APPROVED C7035A1064 HAS 1/2-14 BSP-F INTERNAL MOUNTING THREADS. C7035A1056 HAS 12 FOOT (3.66 METER) LEADWIRES. M1945E Fig. 6. Ultraviolet detectors (minipeepers)

7 3/8 (10) 6 FOOT [1.83 METER] LEAD WIRES (2) MOUNTING BRACKET 1-27/64 (36) 7/8 (22) 3-5/8 (92) 1/2 (13) 9/16 (14) M1944D Fig. 7. Ultraviolet detectors (minipeepers). 1 INCH NPT 2-1/4 (57) 1-1/16 (27) 2-1/4 (57) 4 (102) 4 (102) 2-5/16 (58) 1-13/32 (188) 4-27/32 (123) 10-9/32 (261) 3/4 (19) 7/8 (22) OPENING FOR 1/2-INCH CONDUIT 29/32 (23) 1-19/32 (41) 3/8 INCH NPT 1 ALLOW 9 INCHES (228 MILLIMETERS) CLEARANCE TO SWING OUT THE DETECTOR FOR LENS CLEANING OR SERVICING. 2-11/16 (68) 7-5/8 (194) C7076A M5083C Fig. 8. Ultraviolet detectors (minipeepers)

8 RM7888A Sequence Initiate Standby Purge Pilot: PV Return Pilot: MV Lo Fire Table 5. Sequence Timing for Operation. Pilot Flame Establishing Period (PFEP) * STANDBY and RUN can be an infinite time period. ** PURGE will be determined by the system master controller. *** RM7888A1001 and A1019 are 4 seconds; RM7888A1027 is 10 seconds. Main Flame Establishing Period (MFEP) Pilot Relight Run 10 seconds * ** 10 seconds 10 seconds 5 sec to infinity * 10 seconds * ** 10 seconds 15 seconds * DSI Normal 10 seconds * ** *** * DSI High/Low 10 seconds * ** *** * Stepfire DSI On/Off Stepfire 10 seconds * ** *** * PRINCIPAL TECHNICAL FEATURES The RM7888A provides customary flame safeguard functions while providing significant advancements in the areas of safety, annunciation and system diagnostics. Safety Shutdown (Lockout) Occurs if: 1. INITIATE Period a. Configuration jumper was changed (after 200 hours). b. AC line power errors, see Operation section. c. Four minute INITIATE period is exceeded. 2. STANDBY Period a. Flame signal is present after 240 seconds. b. Pilot valve/1st stage main valve terminal is energized. c. Main valve terminal is energized. d. Internal system fault. e. Flame detected during the last two seconds. f. Limits Complete is not energized after 120 seconds. g. Fire Switch is not energized after eight minutes of hold. h. Flame Proven terminal energized. i. Ignition terminal energized. j. Configuration jumpers select is illegal (during last two seconds). 3. ESTABLISHING Period (PFEP) (Pilot Configuration) a. Pilot/1st stage main valve terminal is not energized. b. No flame is present at end of PFEP. c. Internal system fault. d. Main valve terminal is energized. e. Limits Complete is not energized. Fire is not energized. g. Ignition terminal is not energized for the first ten seconds of PFEP. h. Ignition terminal is energized after the first ten seconds of PFEP. i. Flame Proven terminal is energized for the first ten seconds of PFEP. j. Flame Proven terminal is not energized at the end of PFEP. k. Special Function 2 is not energized after eight minutes (Pilot Configuration). 4. MAIN ESTABLISHING Period. a. Pilot is not energized. b. Pilot/1st stage main valve terminal is not energized. c. Main valve terminal is not energized. d. No flame present. e. Internal system fault. Fire switch is not energized. g. Ignition terminal is energized. h. Flame Proven is not energized. i. Limits Complete is not energized. j. Special Function 2 is not energized. k. Special Function 3 is not energized. 5. RUN Period a. No flame present. b. Flame Proven is not energized. c. Internal system fault. d. Ignition terminal is energized. e. Pilot terminal is energized (Pilot configuration). f. Pilot terminal/main valve first stage is not energized (DSI configuration). g. Limits Complete is not energized. h. Main valve is not energized. 6. Anytime the configuration jumpers are changed while the RM7888A is powered. 7. RELIGHT a. Limits Complete is de-energized. b. Special Function 2 is not energized. c. Special Function 3 is not energized. d. Ignition, pilot, or main is not energized. e. Low Fire is not energized. f. Flame failure. g. Ignition terminal not energized. h. Flame Proven is not energized. 8. WAIT FOR LOW OFF FOR 5 SECONDS a. Limits Complete is not energized. b. Special Function 2 is not energized. c. Flame failure. d. Ignition energized. e. Main energized. f. Flame Proven not energized. g. Pilot not energized. 9. DRIVE TO LOW a. Limits Complete is not energized. b. Special Function 2 is not energized c. Flame failure. d. Ignition energized. e. Main energized. f. Flame Proven is not energized

9 SAFTEY PROVISONS Interal Hardware Status Monitoring The RM7888A analyzes the integrity of the configuration jumper and internal hardware. The LED blinks every four seconds to signify an internal hardware check. Closed Loop Logic Test The test verifies the integrity of all safety critical loads (terminals 8, 9, 10 and 21). If the loads are not energized properly, for example, the main valve terminal is powered during purge, the RM7888A will lockout on a safety shutdown. The RM7888A must react to input changes but avoid the occurrence of nuisance shutdown events. Signal conditioning is applied to line voltage inputs to verify proper op-eration in the presence of normal electrical line noise such as transient high voltage spikes or short periods of line dropout. Signal conditioning is tolerant of synchronous noise (line noise events that occur at the same time during each line cycle). Dynamic Flame Amplifier and Shutter Check Self-checking circuitry tests all electronic components in the flame detection system and amplifier 12 times per minute and shuts down the RM7888A if the detection system fails. Dynamic Amplifiercheck Dynamic Amplicheck circuitry tests the flame signal amplifier during burner operation and shuts down RM7888A if the flame amplifier fails. Dynamic Input Check All system input circuits are examined to make sure that the RM7888A is capable of recognizing the true status of external controls, limits and interlocks. If any input fails this test, a safety shutdown occurs and the fault is annunciated. Dynamic Safety Relay Test Checks the ability of the dynamic safety relay contacts to open and close. Verifies that the safety critical loads (terminals 8, 9, 10 and 21) can be de-energized, as required, by the Dynamic Self-Check logic. Dynamic Self-Check Safety Circuit The microcomputer tests itself and related hardware, and at the same time, the safety relay system tests the microcomputer operation. If a microcomputer or safety relay failure occurs and does not allow proper execution of the self-check routine, safety shutdown occurs and all safety critical loads will be deenergized. Expanded Safe-Start Check The conventional safe-start check, which prevents burner startup if flame is indicated at start-up, is expanded to include a flame signal check during STANDBY, a safety critical load check, a Limits Complete check, and Fire check. Off Cycle (Standby) Flame Signal Check The flame detection subsystem (flame detector and amplifier) is monitored during STANDBY. If a flame simulating condition or an actual flame exists for 40 seconds in STANDBY, a safety shutdown occurs and startup is prevented. If the flame signal exists at any time after 40 seconds during STANDBY, a safety shutdown occurs and is annunciated. A shutter-check amplifier and self-checking detector are energized continuously during STANDBY and the last two seconds of STANDBY. If a flame exists, a safety shutdown will occur. An Amplicheck Amplifier is energized continually through STANDBY to detect any possibility of a runaway detector or a flame. If either situation happens, a safety shutdown will occur. A standard amplifier is energized continually through STANDBY to detect any possibility of a runaway detector or a flame. If either situation happens, a safety shutdown will occur. Tamper Resistant Timing Logic Safety and logic timings are inaccessible and cannot be altered or defeated. Alarm Operation This output will supply power to the system master and/ or an external alarm indicator such as a bell or buzzer. The alarm is turned on anytime a lockout has occurred and the lockout condition has not been cleared. The alarm output is also turned on when the reset button is pressed and held for more than four seconds. The status of this output is not monitored by the relay module. First-Out Annuciation and Self- Diagnostics Sequence Status Lights (LEDs) provide positive visual indication of the program sequence:,,, MAIN and ALARM. The green LED blinks every four seconds, signifying that the RM7888A hardware is running correctly. Optional Multi-function Keyboard Display Module shows elapsed time during IGNITION and MAIN IGNITION. As an additional troubleshooting aid, it provides RM7888A SAFETY PROVISIONS sequence timing, diagnostic information, and historical information when a safety shutdown or hold or normal operation occurs. First-out Annunciation reports the cause of a safety shutdown or identifies the cause of a failure to start or continue the burner control sequence with an English text and numbered code via the Keyboard Display Module. It monitors all field input circuits, including the flame signal amplifier and output circuits. The system distinguishes modes of failure and detects and annunciates difficult-to-find intermittent failures. Self-diagnostics add to the First-out Annunciation by allowing the RM7888A to distinguish between field (external device) and internal (system related) problems. Faults associated within the flame detection subsystem or the RM7888A are isolated and reported by the optional Keyboard Display Module. See Hold and Fault Message Summary in the Checkout and Test, form

10 Interlock Requirements The following interlock inputs are provided. Limits Complete (Terminal 7) This input provides an indication of the status of an interlock string. If this input is energized, it is permissible to operate through a burner sequence. The burner sequence does not leave the Standby state if the Limits Complete signal is deenergized. If this input becomes de-energized after leaving the Standby state, one or more interlocks are open and the burner sequence is either recycled or a lockout occurs as defined for the particular burner Fire (Terminal 18) This input will provide an indication of the low firing rate position. If this input is energized, the motor position is assumed by the relay module to be at the Low Fire position; otherwise, the motor position cannot be determined if this input is de-energized. This signal is readable in any burner operating state without regard to the status of the special function signals or the Limits Complete signal. The RM7888 does not perform a test to assure that the Low Fire input signal becomes energized when the High Fire motor control is commanded. For example, the RM7888 will not detect a Low Fire input that is jumpered or continuously energized without regard to the actual motor position. The High Fire position is not confirmed by a separate high fire input at the RM7888. The system master control is responsible for the High Fire proving and purging of the combustion unit. INSTALLATION WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE, SEVERE INJURY, OR DEATH. To prevent possible hazardous burner operation, perform verification of safety requirements each time a control is installed on a burner. When Installing This Product Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition. 2. Check the ratings given in the instructions and marked on the product to make sure the product is suitable for your application. 3. Installer must be a trained, experienced, flame safeguard service technician. 4. After installation is complete, check out the product operation as provided in these instructions. CAUTION To prevent electrical shock and equipment damage, disconnect the power supply before beginning installation. More than one power supply disconnect may be involved. 1. To prevent electrical shock and equipment damage, disconnect the power supply before beginning installation. More than one power supply disconnect may be involved. 2. Wiring connections for the RM7888A are unique; therefore, refer to Fig. 10 or the correct specifications for proper subbase wiring. 3. Wiring must comply with all applicable codes, ordinances and regulations. 4. Wiring, where required, must comply with NEC Class 1 (Line Voltage) wiring. 5. Loads connected to the RM7888A must not exceed those listed on the RM7888A label or the specifications (see Table 1). 6. Limits and interlocks must be rated to carry and break current simultaneously to the ignition transformer, pilot valve, and main fuel valve(s). 7. All external timers must be listed or component recognized by authorities who have jurisdiction for the specific application. IMPORTANT: 1. For on-off gas-fired systems, some authorities who have jurisdiction prohibit the wiring of any limit or operating contacts in series between the flame safeguard control and the main fuel valve(s). 2. Two detectors can be connected in parallel, with the exception of the Solid State detectors (C7915, C7927, C7962 and C7961). 3. This equipment generates, uses and can radiate radio frequency energy, and if not installed and used in accordance with the instructions, may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device of part 15 of FCC rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area may cause interference, in which case the users, at their own expense, may be required to take whatever measures are required to correct this interference. 4. This digital apparatus does not exceed the Class A limits for radio noise of digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications. 5. RM7888A cannot be connected in parallel without isolation circuits to isolate input and output circuits. Humidity Install the RM7888A where the relative humidity never reaches the saturation point. The RM7888A is designed to operate in a continuous, noncondensing moisture environment with a maximum 85 percent relative humidity. Condensing moisture can cause a shutdown. Vibration Do not install RM7888A where it could be subjected to vibration in excess of 0.5G continuous maximum vibration. Weather The RM7888A is not designed to be weather tight. If installed outdoors, the RM7888A must be protected by an approved weather-tight enclosure. Mounting Wiring Subbase For installation dimensions, see Fig

11 1. Mount the subbase in any position except horizontally with the bifurcated contacts pointing down. The standard vertical position is recommended. Any other position decreases the maximum ambient temperature rating. 2. Select a location on a wall, burner or in an electrical panel. The Q7800 can be mounted directly in the control cabinet. Be sure to allow adequate clearance for servicing, installation, access and removal of RM7888A, dust cover, flame amplifier, flame amplifier signal voltage probes, electrical signal voltage probes and electrical field connections. 3. For surface mounting, use the back of the subbase as a template to mark the four screw locations. Drill the pilot holes. 4. Mount the subbase securely using four No. 6 screws. L1 (HOT) 1 WIRING 1. a. For the internal block diagram of the RM7888A, see Fig. 9. b. For proper subbase wiring, refer to Fig. 10. c. For proper remote wiring of the Keyboard Display Module; refer to the Specifications for the Keyboard Display Module ( ), or Extension Cable Assembly ( ). 2. Disconnect the power supply from the main disconnect before beginning installation to prevent electrical shock and equipment damage. More than one disconnect may be involved. 3. All wiring must comply with all appropriate electrical codes, ordinances and regulations. Wiring, where required, must comply with NEC Class 1 wiring. L2 120 Vac 4 CONFIGURATION JUMPERS SIGNAL TEST JACK L2 RESET PUSHBUTTON MICROCOMPUTER 2K TEST PLUG-IN AMPLIFIER F G 22 3K STATUS LEDs RELAY DRIVE CIRCUIT 4K 5K 7K RELAY STATUS FEEDBACK AND LINE VOLTAGE INPUTS SAFETY RELAY CIRCUIT 1K DDL DDL COMMUNICATIONS OPTIONAL KEYBOARD DISPLAY MODULE RS REMOTE RESET SUPPLY 3K1 6K1 1K1 5K1 2K2 CONTROL ALARM AIRVALVE IGNITION 2 SPECIAL FUNCTION 1 6 4K1 8 LIMITS COMPLETE 7 2K2 7K MAIN VALVE PROVEN LOW FIRE SWITCH SPECIAL FUNCTION 2 SPECIAL FUNCTION 3 8K1 8K2 9K2 HIGH FIRE COMMON MODULATE 9K1 LOW FIRE INDICATES FEEDBACK SENSING OF RELAY CONTACT AND LINE VOLT INPUTS FIELD WIRING INTERNAL WIRING 2 20 SPECIAL FUNCTION PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. 120 VAC INPUT FROM SYSTEM MASTER CONTROLLER REFER TO TABLE 1 AND FIGURE 8. M9496D Fig. 9. RM7888A internal block diagram

12 L2 L1 (HOT) 1 MASTER SWITCH Q7800 SUBBASE G 12 L2 13 HIGH FIRE COMMON SERIES 90 FIRING RATE MOTOR B R SERIES 90 CONTROLLER B R 120V ALARM 3 14 LOW FIRE W W LIMITS AIR VALVE 4 5 (L1) MODULATE SPECIAL FUNCTION SPECIAL FUNCTION LOW FIRE SWITCH 8 19 SPECIAL FUNCTION 3 MAIN FUEL VALVE(S) 9 20 SPECIAL FUNCTION 4 IGNITION INDICATION EXTERNAL CONTROLLER DETECTOR F 22 L2 L1 FOR DIRECT SPARK IGNITION (OIL OR GAS) 1ST STAGE FUEL VALVE 8 L2 2ND STAGE FUEL VALVE V SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. IGNITION 10 M9495A Fig. 10. RM7888A wiring diagram. 4. Recommended wire size and type: a. Use 14, 16, or 18 AWG copper conductor (TTW60C or THW75C or THHN90C) 600 volt insulation wire for all line voltage terminals. For high temperature installations, use wire selected for a temperature rating above the maximum operating temperature. All leadwires must be moisture resistant. b. Keyboard Display Module For communications purposes, use an unshielded 3-wire twisted cable if the leadwire run and noise conditions permit; however, some installations may need up to five wires; three for communications and two for remote reset (either in a single cable or separate cables for communications or remote reset) or use Belden 8771 shielded cable or equivalent. The Keyboard Display Module, DATA CONTROLBUS MODULE (for remote mounting or communications) or Modbus Module must be wired in a daisy-chain configuration, 1(a)- 1(a), 2(b)-2(b), 3(c)- 3(c)). The order of interconnection of all the devices is not important. Be aware that modules on the closest and farthest end of the daisy chain configuration require a 120-ohm (1/4 watt minimum) resistor termination across terminals 1 and 2 of the electrical connectors for connections over 100 feet [30 meters]. c. DATA CONTROLBUS or MODBUS MODULE For communications purposes, use an unshielded 3-wire twisted cable if the leadwire run and noise conditions permit; however, some installations may need up to five wires; three for communications and two for remote rest (either in a single cable or separate cables for communications or remote reset) or use Belden 8771 shielded cable or equivalent. The Keyboard Display Module, DATA CONTROLBUS MOD- ULE (for remote mounting or communications) or Modbus Module must be wired in a daisy-chain configuration, 1(a)-1(a), 2(b)-2(b),3(c)-3(c)). The order of interconnection of all the devices is not important. Be aware that modules on the closest and farthest end of the daisy chain configuration require a 120-ohm (1/4 watt minimum) resistor termination across terminals 1 and 2 of the electrical connectors for connections over 100 feet [30 meters]. d. Remote Reset Use 22 AWG or greater twisted pair wire, insulated for low voltage

13 5. Recommended grounding practices: a. Use earth ground to provide a connection between the subbase and the control panel or the equipment. The earth ground wire must be capable of conducting the current to blow the 15A fast blow fuse (or breaker) in the event of an internal short circuit. The RM7888A needs a low impedance ground connection to the equipment frame which, in turn, needs a low impedance connection to earth ground. For a ground path to be low impedance at RF frequencies, the connection must be made with minimum length conductors that have a maximum surface area. Wide straps or brackets are preferred rather than leadwires. Make sure that mechanically tightened joints along the ground path, such as pipe or conduit threads or surfaces held together with fasteners, are free of nonconductive coatings and are protected against mating surface corrosion. b. Keyboard Display Module, DATA CONTROLBUS MODULE or Modbus Module The shield, if used, should be connected to the signal ground terminal 3(c) provided as part of the 7800 SERIES device ControlBus connection. The shield should be connected at both ends to ground. c. RM7888A Each RM7888A will have an earth ground terminal that must be grounded to the metal control panel with wire as short as practical. Each ground wire must be capable of carrying a fault current equal to the rating of the protective fuse 15A fast blow. A 14 AWG copper conductor is adequate, but wide straps or brackets are preferred to leadwires. 6. Recommended wire routing: a. Flame detector leadwires: (1) Do not run high voltage ignition transformer wires in the same conduit with flame detection wiring. (2) Do not route scanner wires in a conduit with line voltage circuits. (3) Enclose scanner wires without armor cable in metal cable or conduit. (4) Follow directions given in flame detector instructions. b. DATA CONTROLBUS MODULE or Modbus Module: (1) Do not run high voltage ignition transformer wires in the same conduit or in close proximity to the MODULE wiring. (2) Do not route MODULE wires in conduit with line voltage circuits. c. Keyboard Display Module: (1) Because the VFD is powered from a low voltage, energy limited source, mount it outside a control panel, without using special wiring procedures, if it is protected from mechanical damage. d. Remote Reset: (1) Do not run high voltage ignition transformer wires in the same conduit with the Remote Reset wiring. (2) Do not route Remote Reset wires in the same conduit with line voltage circuits. 7. Maximum wire lengths: a. For the flame detector leadwires, the maximum flame sensor leadwire length is limited by the flame signal strength. b. For the Remote Reset leadwires, the maximum length of wire is 1000 feet to a Remote Reset pushbutton. c. For the DATA CONTROLBUS or MODBUS MOD- ULE, the maximum cable length depends on the number of system modules connected, the noise conditions and the cable used. The maximum length of all interconnecting wire is 1000 feet [305 meters]. 8. Make sure loads do not exceed the terminal ratings. Refer to the label on the RM7888A or to the ratings in the specifications; see Table Check the power supply circuit. The voltage and frequency tolerance must match those of the RM7888A. A separate power supply circuit may be required for the RM7888A with the required disconnect means and overload protection added. 10. Check all wiring circuits and complete the Static Checkout before installing the RM7888A on the subbase: see Table Install all electrical connectors. 12. Restore power to the panel. ASSEMBLY Mounting the RM7888A For installation dimensions, see Figs. 1 Relay Module Mounting (Figs. 11 and 12) 1. Mount RM7888A vertically, see Figs. 11 or 12, or mount horizontally with the knife blade terminals pointing downward. When mounted on the Q7800A, the RM7888A must be in an electrical enclosure. 2. Select the location in the electrical enclosure. Be sure to allow adequate clearance for servicing, installation and removal of the RM7888A, Keyboard Display Module, flame amplifier, flame amplifier signal voltage probes, electrical signal voltage probes and electrical connections. a. Allow an additional two inches below the RM7888A for the flame amplifier mounting. b. Allow an optional three-inch minimum to both sides of the RM7888A for electrical signal voltage probes. 3. Make sure no subbase wiring is projecting beyond the terminal blocks. Tuck in wiring against the back of the subbase so it does not interfere with the knife blade terminals or bifurcated contacts. IMPORTANT: The RM7888A must be installed with a plug-in motion rather than a hinge action

14 3. Make sure the Keyboard Display Module is firmly in place. Fig. 13. Keyboard Display Module mounting. Fig. 11. Electrical panel installation. Mounting the Data Controlbus Module, Modbus Module or the Extension Cable Assembly (Figs. 14 and 15) 1. Align the two interlocking ears with the two mating slots on the RM7888A. 2. Insert the two interlocking ears into the two mating slots and push on the lower corners of the DATA CONTROL- BUS MODULE, Modbus module or Extension Cable Assembly to secure it to the RM7888A. 3. Make sure the modules are is firmly in place. Fig. 12. Wall or burner installation. 4. Mount the RM7888A by aligning the four L-shaped corner guides and knife blade terminals with the bifurcated contacts on the wiring subbase and securely tightening the two screws without deforming the plastic. Mounting the Keyboard Display Module (Fig. 13) 1. Align the two interlocking ears of the Keyboard Display Module with the two mating slots on the RM7888A. 2. Insert the two interlocking ears into the two mating slots and, with a hinge action, push on the lower corners of the Keyboard Display Module to secure it to the RM7888A. Fig. 14. DATA CONTROLBUS MODULE mounting

15 Installing the Plug-in Flame Signal Amplifier 1. Disconnect the power supply before beginning the installation to prevent electrical shock and equipment damage. More than one disconnect may be involved. 2. Align the amplifier circuit board edge connector with the keyed receptacle on the RM7888A. Make sure the amplifier nameplate faces away from the Relay Module. 3. Push in the amplifier until the circuit board is fully inserted into the receptacle and then push the amplifier toward the RM7888A retaining clasp. 4. Make sure the amplifier is firmly in place. 5. Perform all required checkout tests. Fig. 15. Extension Cable Assembly mounting. Remote Mounting the Keyboard Display Module (Fig. 16) 1. The Keyboard Display Module can be mounted either on the face of a panel door or other remote locations. A DATA CONTROLBUS MODULE or an Extension Cable Assembly is required to connect RM7888A to a remote Keyboard Display Module. 2. When mounting the Keyboard Display Module on the face of the door panel, closely follow these instructions: a. Select the location on the door panel for flush mounting. Pay attention to the insertion dimension of the two Keyboard Display Module screws, two interlocking ears and the two plug-in connectors to allow for sufficient clearance (1/4 in. [6 mm] minimum) inward from the surface of the door panel. b. Mark the two screw locations, two interlocking ear locations and the two plug-in connector locations. Drill the pilot holes for the mounting screws. Provide for two holes on the door panel for the interlocking ears and two holes for the plug-in connectors. c. Mount the Keyboard Display Module on the door using two no. 4 screws. 3. When mounting the Keyboard Display Module on a wall or remote location, use part number , Remote Mounting Bracket. a. Using the Remote Mounting Bracket as a template, mark the four screw locations and drill the pilot holes. b. Mount the Remote Mounting Bracket using four no. 6 screws. c. Mount the Keyboard Display Module by aligning the two interlocking ears with the two mating slots on the Remote Mounting Bracket. d. Insert the two interlocking ears into the two mating slots. Push on lower corners of the Keyboard Display Module to secure it to the Remote Mounting Bracket. e. Make sure the Keyboard Display Module is firmly in place. Fig. 16. Remote mounting of Keyboard Display Module

16 Installing the Flame Detector (Fig. 18) Table 4 lists the flame detection systems available for use with the RM7888A. Make sure the correct combination of amplifier and flame detector(s) is used. Proper flame detector installation is the basis of a safe and reliable flame safeguard installation. Refer to the instructions packed with the flame detector and the equipment manufacturer instructions. Keep the flame signal leadwires as short as possible from the flame detector to the wiring subbase. Capacitance increases with leadwire length, decreasing the signal strength. The maximum permissible leadwire length depends on the type of flame detector, leadwire and conduit. The ultimate limiting factor in the flame signal is the flame detector leadwire. Fig. 17. Flame signal amplifier mounting

17 INFRARED (C7915) BLUE F WHITE G ULTRAVIOLET (C7027/C7035/C7044) BLUE F 1 WHITE G C7076A,D ULTRAVIOLET DETECTOR F F G G 3a SHUTTER SHUTTER L2 REMOTE SENSOR 3b L1 L2 7 2b 8 2a SERIES EARTH GROUND C7076A OR C7076D TERMINAL BLOCK L1 (HOT) L2 (COMMON) 5 22 SOLID STATE SELF-CHECKING ULTRAVIOLET (C7012E,F) SOLID STATE ULTRAVIOLET (C7012A,C) BLUE F 2 YELLOW G 2 WHITE 22 F G BLUE YELLOW L2 L1 L2 WHITE BLACK BLACK L1 L2 BLACK BLACK ROD X F PHOTOCELL X F X G X G 1 DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL AND THE WHITE MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE. 2 DETECTOR LEADS ARE COLOR CODED. THE BLUE LEAD MUST BE CONNECTED TO THE F TERMINAL AND THE YELLOW MUST BE CONNECTED TO THE G TERMINAL. THE UV SENSING TUBE IS POLARITY SENSITIVE. REVERSING THE LEADS EVEN MOMENTARILY CAN DAMAGE OR DESTROY THE UV TUBE. M1969C Fig. 18. Flame detector wiring. OPERATION WARNING The user of the RM7888A is responsible for providing an effective purge that meets the approval of the authority having jurisdiction for a particular installation. Failure to provide an effective purge can result in a fire or explosion that can cause damage, serious injury or death. Sequences of Operation The RM7888A has five user selectable operating sequences: Pilot PV Return; Pilot MV Lo Fire; Direct Spark Ignition (DSI) Normal Operating Sequence; DSI High/Low Stepfire Operating Sequence and DSI Off/On Stepfire Operating Sequence. Each operating sequence will be discussed in detail

18 CAUTION The user selects the appropriate control sequence by clipping configuration jumpers. Sequence selection must be done correctly. Failure to select the sequence correctly can be hazardous. Follow instructions in this specification. SELECTABLE CONFIGURATION JUMPERS Selectable Site-Configurable Jumpers The RM7888A has five site-configurable jumper options and three options that will result in a lockout, see Fig. 19 and Table 6. The site-configurable jumpers should be clipped with side cutters and the resistor removed from the Relay Module. M7861A Fig. 19. Selectable site-configurable jumpers. Table 6. Site-Configurable Jumper Options. Jumper J1 J2 J3 RM7888A Action Intact Intact Intact Default, selects the Pilot Configuration Burner Sequence, including the Pilot Relight Function.(PV Return) 1 Intact Clipped Clipped Selects DSI Normal Burner Sequence. 1 Clipped Intact Clipped Selects DSI High/Low Stepfire Burner Sequence. 1 Clipped Clipped Intact Selects DSI Off/On Stepfire Burner Sequence. 1 Intact Intact Clipped Selects Pilot Configuration Burner Sequence, but excludes the Pilot Relight Function.(MV Lo Fire) 1. Intact Clipped Intact Illegal; will result in a lockout. Clipped Intact Intact Illegal; will result in a lockout. Clipped Clipped Clipped Illegal; will result in a lockout. 1 Each operating sequence is described individually in the Operation section of this specification. Read the appropriate operating sequence section carefully before clipping jumpers. The sequence selection cannot be reversed. Pilot Configuration Operating Sequence The Pilot Configuration Operating Sequence has two distinct operating sequences that are entered from the Standby/ Standby Purge states. The sequences are: a. PV Return: allows the control to reestablish the pilot and de-energize the main flame in response to the system heating requirements. b. MV Lo Fire: will not allow the pilot to be re-established once RUN has been entered; the main valve remains energized with Lo Fire being the lowest firing rate allowed. See Table 7 for the state names, the text that appears on the S7800 Keyboard Display Module, and the purpose. Pilot Configuration State Name Table 7. Pilot Configuration Operation Sequence States. S7800 Keyboard Display Module Displayed Text Purpose of State Initiate (See below) The Initiate state allows the relay module to complete initialization after a powerup or whenever a problem that would prevent normal operation (such as an ac line problem), the Initiate state is entered. Initiate INITIATE mm:ss Displayed during timed portion of the Initiate state. Initiate INITIATE HOLD: AC Displayed during Initiate state if the ac frequency is low or noise is present. (AC Freq/Noise) Initiate INITIATE HOLD: AC (AC Line Dropout) Displayed during Initiate state if the ac line power was lost

19 Pilot Configuration State Name Initiate INITIATE HOLD: AC Displayed during Initiate state if the ac frequency is high. (AC Frequency) Initiate INITIATE HOLD: AC Displayed during Initiate state if the ac line voltage is low. (Low Line Voltage) Off STANDBY Remaining idle until valid input(s) are received. All safety loads are commanded off. STANDBY HOLD: F/G Displayed when a flame is detected. (Flame Detected) STANDBY HOLD: T7 Displayed when a call for operation is active and the Limits Complete signal is off. (Lockout ILK) PURGE HOLD: T18 Displayed when a call for operation is active and the Low Fire Switch signal is off. (Low Fire Switch) Purge PURGE 01:00 Purge at high fire. All safety loads are commanded off. Display indicates Purge type 1 = Purge. Control Cool PURGE 02:00 Purge at the motor position commanded by the modulating control. All safety loads are commanded off. Display indicates Purge type 2 = Control Cool. Low Combustion Air Only PURGE 03:00 Purge at low fire. All safety loads are commanded off. Display indicates Purge type 3 = Low Combustion Air Only. Pilot Ignition IGN mm:ss Establish a pilot flame. Display shows state and elapsed time. At end of Pilot Ignition timed state, timer will stop and display will show final time while a hold exists. Main Train Fuel On MAIN IGN 00:00 Allow for main valve operators to be placed into the normal operating condition. Display shows state with zero elapsed time while waiting for a hold condition(s). Burner Fuel Valve MAIN IGN 00:ss Open (Pilot Timeout) Release to Modulation RUN Table 7. Pilot Configuration Operation Sequence States. (Continued) S7800 Keyboard Display Module Displayed Text Purpose of State Establish a main flame and drop the pilot flame. Display will show MFEP state elapsed time. Allow normal operation to take place where a modulating control provides the motor position signal. RUN When special function input terminal 20 is off, relay module will command a Low Fire motor 10 Sec RUN When the Low Fire input becomes energized for a continuous time period of 10 seconds, the sequence will leave the Release to Modulation state and proceed to the Pilot Relight state (PV Return sequence only). Pilot Relight PVHOLD IGN 00:ss Re-establish the pilot flame and drop the main flame. Display indicates elapsed time in this timed state (PV Return sequence only). Low Off 5 Sec. PVHOLD IGN 01:00 Wait for the Low Fire input signal to become de-energized for a continuous period of five seconds and then proceed to the Main Train Fuel On state after driving back to the Low Fire position. Display indicates that sequence is in Pilot Hold State type 1 = Waiting for Low Off 5 Sec. Drive to Low PVHOLD IGN 02:00 Commands the low fire motor position and waits until the Low Fire input becomes energized before proceeding to the Main Train Fuel On state. Display indicates that sequence is in Pilot Hold State type 2 = Waiting for Low Fire On. Pilot Configuration Sequence of Operation WARNING The user of the RM7888A is responsible for providing the correct signal to each special function input terminal and must make sure that safety is not compromised if an incorrect special function input is applied. Initiate The RM7888A enters the INITIATE sequence when the Relay Module is powered. The RM7888A also enters the INITIATE sequence if the Relay Module verifies voltage fluctuations of +10/-15 percent or frequency fluctuations of ±10 percent during any part of the operating sequence. The INITIATE sequence lasts for ten seconds unless the voltage or frequency tolerances are not met. When the tolerances are not met, a hold condition will be initiated and will be displayed on the Keyboard Display Module for at least five seconds. When the tolerances are met, the INITIATE sequence will restart. If the

20 condition is not corrected and the hold condition exists for four minutes, the RM7888A will lock out. Causes for hold conditions in the INITIATE sequence are: AC line dropout is detected. AC line noise that can prevent a sufficient reading of the line voltage outputs. Brownouts caused by a low line voltage. Standby The Standby states include Standby-Off, Standby-Purge, Standby-Control Cool, and Standby-Low Combustion Air Only, and Standby-Hold. All Standby states command the ignition, pilot and main off and will lockout if the feedback signals indicate that one of those terminals is energized. The Flame Proven output will be commanded off without regard to the current Flame Sensed signal. After the first three seconds of Standby, if the Flame Sensed signal indicates flame, the special function inputs will be ignored, the Air Valve will be commanded off and the motor position commanded to Low Fire. The alarm output will be commanded off. The Standby state selected is based on the state of special function inputs 1, 2, 3 and 4 (terminals 6, 17, 19 and 20). A three-second transition period runs when the Standby state is entered. This time period allows enough time for the master system controller to set up the desired combination of special function input signals so when the time period expires, the required motor position command and air valve output status are commanded. During the time period, the motor control is commanded to the Low Fire position, the Air Valve is commanded off, the special function input terminals are ignored, and the safety loads (Ignition, Pilot and Main Valve) are commanded off immediately upon entering Standby. When special function 1 is energized, a request for burner operation is in effect, the Air Valve will be commanded off and the LowFire motor position commanded. In this case, special functions 2, 3, and 4 are ignored. The burner will sequence to the Pilot Ignition state as soon as the Low Fire input and the Limits Complete input are energized. WARNING The user of the RM7888A is responsible for providing an effective purge that meets the approval of the authority having jurisdiction for a particular installation. The RM7888A does not directly monitor the presence or absence of airflow and cannot guarantee that the air valve or fan is working. Failure to provide an effective purge can result in a fire or explosion that can cause damage, serious injury or death. Standby-Hold The RM7888A has a request to sequence out of standby (special function terminal 1 is energized), but a condition such as a de-energized Low Fire input or Limits Complete input signal keeps the sequence in Standby. When Special Function 1 is energized, the sequence will hold for eight minutes while waiting for the Low fire signal to become energized, with an alarm after four minutes of hold. The sequence will hold for 120 seconds while waiting for the Limits Complete signal to become energized. If either time limit expires, a lockout will occur. When Special Function 1 is de-energized, one of four Standby states are possible. The Standby state in effect depends on the status of the special function inputs. The four Standby states are: 1. Off: the relay module is commanding the Low Fire motor position and the Air Valve off. 2. Purge: The relay module is commanding the High Fire motor position and the Air Valve on. 3. Control Cool: The relay module is commanding the modulated motor position and the Air Valve on. 4. Low Combustion Air Only: The relay module is commanding the Low Fire motor position and the Air Valve on. If Special Function inputs 2, 3 and 4 are all de-energized, the Standby-Off state is in effect: the Air Valve is commanded off and the Low Fire state is ordered. During Standby/Standby-Purge states, when special function 1 is de-energized, special function terminals 2, 3 and 4 provide a signal that requests that the RM7888A command a particular motor position and Air Valve status. If any one or more of the special function inputs (terminals 17, 19, or 20) is energized, a Standby-Purge state is in effect with the Air Valve commanded on and either Low Fire, High Fire, or the modulated position commanded (see Table 8). Table 8 defines the combinations of special function inputs and corresponding output state (Air Valve and Motor Output) during Standby. Pilot Configuration Ignition Trials (PV Return and MV Lo Fire Sequences) Pilot Ignition State Pilot Ignition is entered only from the Standby state with the Limits Complete and Low Fire input signals energized, Special Function input 1 (terminal 6) energized and the Air Valve either on or off, depending on which Standby state preceded the Pilot Ignition state. At the start of the Pilot Ignition state, the ignition and pilot outputs are commanded on, Low Fire is commanded, and the Air Valve is commanded off. The RM7888A will lockout if the Low Fire input becomes de-energized after the first two seconds of the Pilot Ignition state. A one- to two-second transition state precedes the Pilot Ignition state so the Low Fire switch has at least three seconds to stabilize. This reduces the possibility of a contact bounce causing a lockout. The RM7888A will lockout if the Limits Complete input becomes deenergized. For the first ten seconds, the Pilot Ignition state attempts to establish a pilot flame. If, at the end of ten seconds, a pilot flame has not been established, a lockout will occur. Otherwise, with a flame established, the igniter is commanded off, the Flame Proven output is commanded on and the pilot flame continues. This pilot state, with only the pilot output on and a pilot flame proven, will continue for at least five seconds, but may continue indefinitely depending on the status of the special function input terminals. If a flameout occurs any time after this point in the burner sequence, a lockout will occur

21 Special Function 2 (Terminal 17) Table 8. Special Function Inputs/Output States During Standby. Special Function 3 (Terminal 19) Special Function 4 (Terminal 20) Air Valve Output De-energized De-energized De-energized De-energized Low Fire De-energized De-energized Energized Energized High Fire De-energized Energized Energized Energized Modulate Energized Energized Energized Energized Low Fire De-energized Energized De-energized Energized Modulate Energized De-energized De-energized Energized Low Fire Energized De-energized Energized Energized Low Fire Energized Energized De-energized Energized Low Fire Motor Position Commanded WARNING The Flame Proven output is an RM7888 safety output, whose output status is monitored by RM7888A. This output is to be used by external equipment that can respond to the signal. The end user must assure that the Flame Proven output cannot be misinterpreted. Misinterpretation of this signal could create a hazardous situation, resulting in fire or explosion that can cause damage, serious injury or death. Pilot Ignition-(Hold) After the five second period following the ten-second pilot establishing period has expired, the RM7888A will respond to special functions 2 and 3. If special functions 2 and 3 are both de-energized, or if special function 2 is deenergized and special function 3 is energized, the pilot state will continue indefinitely. If, after four minutes, special function 2 does not become energized, the alarm will be commanded on. If special function 2 is still de-energized after an additional four minutes (eight minutes total), a lockout will occur. If special function 2 becomes energized and special function 3 is de-energized, the pilot state will sequence to the Main Train Fuel On state. If special functions 2 and 3 both become energized at the same time, the pilot state will sequence to the Burner Fuel Valve Open/Pilot Timeout state, bypassing the Main Train Fuel On state. Main Train Fuel On At Main Train Fuel On, the Air Valve and the Main Fuel are commanded on. The motor position will continue at Low Fire, and the pilot valve will stay on. The sequence will lockout if either the Low Fire input, or the Limits Complete deenergize, or a flame failure occurs. The Main Train Fuel On state will proceed to the Burner Fuel Valve Open/Pilot Timeout state as soon as special function 3 becomes energized in addition to special function 2. If special function 2 becomes de-energized after the first two seconds while in the Main Train Fuel On state, a lockout will occur. After four minutes, if special function 3 does not become energized, the alarm will be commanded on. After an additional four minutes, if special function 3 is still de-energized, a lockout will occur. Burner Fuel Valve Open/Pilot Timeout (Main Flame Establishing) During Burner Fuel Valve Open/Pilot Timeout, the main flame will be established and the pilot extinguished. When the Burner Fuel Valve Open/Pilot Timeout state is entered, the pilot, main, and Air Valve will be commanded on, the ignition commanded off, the motor position to low fire, and a ten second timer starts. A lockout will occur if the Low Fire input or the Limits Complete becomes de-energized, or a flame failure occurs, or Flame Proven output is de-energized. After the first two seconds, a lockout will occur if the special function 2 or 3 de-energize. At the end of the ten second period, the pilot is commanded off and a five second minimum flame stabilization period begins. When the stabilization period is completed, the RM7888A will respond to the status on special function 4. If special function 4 is energized, the sequence will proceed to the Release to Modulation state (Run state). If special function 4 is de-energized, the sequence will remain indefinitely at the Main Flame Low Fire state. A lockout will occur if the Pilot, Ignition or Main Valve outputs are not in the commanded states, if the flame is lost, if special function 2 or 3 becomes de-energized, or Flame Proven output is deenergized. Release to Modulation State (Run State) When the Release to Modulation state is entered, the only change in the commanded output status is the motor position; it is commanded to Modulate instead of Low Fire. The sequence will lockout if the Limits Complete becomes deenergized, a flame failure occurs, special function 2 or 3 becomes de-energized, or Flame Proven output is deenergized. If the site configurable jumpers are configured to include Pilot Relight (PV Return Sequence) Pilot Relight is initiated as follows. When the motor position is Modulate and the Low Fire input is energized during the Release to Modulation state for a continuous time period of ten seconds, the sequence will proceed to the Pilot Relight state. Normally, the requirements of the process will be sufficient to keep the modulating control above the Low Fire position. If the site configurable jumpers are configured to exclude Pilot Relight (MV Lo Fire Sequence), Pilot Relight will not be initiated; the burner modulates to Low Fire during the Run state and remains there until the RM7888A is commanded off (Standby). Run-Low Fire (part of Run State) If special function 4 becomes de-energized during the Run state, the sequence will command the motor position to Low Fire and start a 240-second timer. If Fire input fails

22 to energize or becomes de-energized after the time period has expired while special function 4 remains deenergized, the alarm output will be made active. If special function 4 becomes energized, the time period measurement will end and the normal Release to Modulation (Run) state will be active. Pilot Relight PV Return Sequence Only When the Pilot Relight state is entered, the Ignition, Pilot, Main, and Air Valve will be commanded on, the motor position will be commanded to Low Fire and a ten second timer will be started. Flame Proven remains on. The sequence will lockout if the Limits Complete deenergizes or a flame failure occurs. Lockout will also occur if the Low Fire input or special function 2 or 3 becomes deenergized during Pilot Relight. At the end of the ten-second period, the Wait for Low Off state is entered. The ignition, main valve and Air Valve are commanded off, the Pilot remains commanded on, and the motor is commanded to the Modulate position. The Modulate position is commanded to detect a process load increase by noticing that the modulating control has requested a position other than the Low Fire position. If the Low Fire input is de-energized during the Wait for Low Off state for a continuous time period of five seconds, the sequence will proceed to the Drive to Low Fire state. Otherwise, the sequence will remain in the Wait for Low Off state indefinitely while waiting for the modulating control to request more heat by commanding a motor position from Low Fire that signals that the process load has increased and the burner will sequence back to the Run state. The sequence will lockout if the special function 2 (terminal 17) becomes deenergized, but will ignore special functions 3 and 4. Drive to Low Fire The purpose of the Drive to Low Fire state is to drive the motor position back to Low Fire in preparation for return to main fuel. When the Drive to Low Fire Position state is entered, the Ignition, Main Valve and Air Valve are commanded off, the Pilot is commanded on, the motor position is commanded to the Low Fire position and a 15-second timer is started. If the 15-second time period expires, the sequence will hold waiting for the Low Fire input to become energized and the alarm output will be commanded on. The sequence will proceed to the Main Train Fuel On state when the Low Fire input becomes continuously energized for three seconds. If special function 2 is de-energized, a lockout will occur. Lockout State The Lockout State is entered when a timed sequence hold expires or a signal is not in the required state. The RM7888A Pilot Configuration sequence description details the conditions under which the sequence will lockout. Pilot Sequence Timing Diagram Fig. 20 shows the timing relationships between the RM7888A inputs and outputs for each sequence state described in the preceding paragraphs. DIRECT SPARK IGNITION (DSI) OPERATING SEQUENCE The Direct Spark Ignition (DSI) configuration has three distinct operating sequences that are entered from the Standby/ Standby Purge states. The sequences are: Normal sequence. High/Low Stepfire sequence. Off/On Stepfire sequence. Each sequence is user-selectable using the configuration jumpers. The sequence that is used is dictated by the requirements of a particular application. Each sequence consists of a burner operating sequence with several states. Normal sequence is used when the application requires the burner flame to be modulated during the Run state. Table 9. DSI Configuration Operation Sequence States. DSI State Name Displayed Text Purpose Normal Part 1 (Main Flame MAIN IGN 00:ss Establish a Low Fire flame. Display shows elapsed time for Normal Part 1. Establishing Period [MFEP]) Normal Part 2 (Main Flame Establishing Period [MFEP]) MAIN IGN 00:ss Allow for main valve operators to be placed into the normal operating condition while at Low Fire position. Display shows elapsed time for Normal Part 2. Normal Part 3 (Run) RUN Allow normal operation to take place where a modulating control provides the motor position signal. High/Low Stepfire Part 1 (Main MAIN IGN 00:ss Establish a Low Fire flame. Display shows elapsed time. Flame Establishing Period [MFEP]) High/Low Stepfire Part 2 (Run) RUN Run with Low Fire flame while commanding Low Fire for an indefinite time period. When the appropriate special function signals are present, the sequence will advance into the HI (Run at High Fire) state. Run High RUN Run with a High Fire flame for an indefinite period. From this state, the sequence can return to the Low Fire state upon command without recycling. Commanded output state is the same as Normal Part 3, but special function signals are different. OFF/ON Stepfire Part 1 (Main MAIN IGN 00:ss Establish a Low Fire flame. Display shows elapsed time. Flame Establishing Period [MFEP]) OFF/ON Stepfire Part 2 (Run) RUN Run with a high fire flame for an indefinite period. Commanded output state is the same as Normal Part 3 but special function signals are different

23 PV Return and MV Lo Fire PV Return Only INPUT & OUTPUT SIGNALS STANDBY STANDBY- PURGE IGNITION 1ST 10 SEC - IGNITION LAST 5- INFINITE SECONDS MAIN TRAIN FUEL ON 0-INFINITE TIME BURNER FUEL VALVE OPEN- TIMEOUT 1ST 10 SEC BURNER FUEL VALVE OPEN- TIMEOUT LAST 5 TO INFINITE RELEASE TO MODULATION RUN: 0 TO INFINITE SEC RELIGHT 10 SEC RELIGHT AFTER 10 SEC WAIT FOR LOW OFF FOR 5 SEC 5 TO INFINITE SEC DRIVE TO LOW FIRE POSITION 2 TO 5 SEC. (WITH 2-3 SEC. AT LOW STABILIZE) RETURN TO MAIN TRAIN FUEL ON STATE MAIN MAIN MAIN MAIN MAIN MAIN ALARM IGNITION- T10 - T8 MAIN- T9 AIR VALVE-T5 PROVEN- T21 ALARM- T3 MOTOR POSITION- T12-T15 L/H/MOD L L L L L MOD L MOD LOW FIRE INPUT- T18 LIMITS COMPLETE- T7 SF1 SPECIAL FUNCTION- T6 SF2 SPECIAL FUNCTION- T17 SF3 SPECIAL FUNCTION- T19 SF4 SPECIAL FUNCTION- T20 SENSED M9497A Fig. 20. RM7888A Relay Module Pilot Sequuence timing diagram. High/Low Stepfire sequence is used when the application requires the burner flame to be switched, on command, between a Low Fire and a High Fire Run state. Off/On Stepfire sequence is used when the application requires the burner flame to be switched, on command, between a Standby state and a Main Flame state. Each DSI operating sequence has several states. See Table 9 for the state names, the text as shown on an S7800A Keyboard Display Module, and a brief description of the state purpose. All three sequences have the Standby state in common. WARNING The user of the RM7888A is responsible for providing the correct signal to each special function input terminal and must make sure that safety is not compromised if an incorrect special function input is applied. Initiate State The Initiate state will be entered when the RM7888A is powered. The sequence will transition to the Standby state after a ten second period. However, if any condition exists that could prevent reliable operation of the RM7888A, the sequence will remain in the Initiate state until the condition is corrected. These conditions include the detection of the loss of ac power, insufficient ac power level, incorrect ac line frequency, and excess noise present on the ac line. A ten second stabilization period occurs after the condition is corrected before the sequence transitions to the Standby state. Also, any condition that is detected will remain annunciated for a minimum of five seconds. Standby State Standby states for the DSI sequences are the same as those for the Pilot sequences. See Pilot Configuration Ignition Trials

24 WARNING The user of the RM7888A is responsible for providing an effective purge that meets the approval of the authority having jurisdiction for a particular installation. The RM7888A does not directly monitor the presence or absence of airflow and cannot guarantee that the air valve or fan is working. Failure to provide an effective purge can result in a fire or explosion, causing damage, serious injury or death. When special function 1 is energized, the RM7888A will sequence to the initial DSI state based on the setting of the configuration jumpers. A hold, as previously defined, will prevent the sequence from exiting the Standby state. Normal Part 1 The Normal Part 1 state is entered only from the Standby state with the Limits Complete signal Fire input on, and special function 1 energized. On entry, the Air Valve will be commanded off, the Ignition and Pilot (Low Fire Valve) outputs are commanded on, and Low Fire position is commanded. The Main Valve and Flame Proven outputs are commanded off. The RM7888A will lockout if Fire input becomes deenergized after the first two seconds of the Normal Part 1 state. A one- to twosecond transition state precedes the Normal Part 1 state so the Low Fire switch has at least three seconds (total) to stabilize. This reduces the chance of a nuisance lockout due to a contact bounce on Fire input. The RM7888A will lockout if the Limits Complete is deenergized. For the first four seconds, the Normal Part 1 state attempts to establish a Pilot (Low Fire Valve) flame. At the end of the first four seconds, the Ignition output is commanded off. If flame has not been established, a lockout will occur. With flame established, an indefinite hold will occur if special function 2 is de-energized and the Flame Proven output is commanded on. Otherwise, with flame established and special function 2 energized, the Normal Part 2 state is entered. WARNING The Flame Proven output is an RM7888A safety output with an output status monitored by the RM7888A. This output is used by external equipment which can respond to the signal. The end user must assure that the Flame Proven output cannot be misinterpreted. Misinterpretation of this signal could create a hazardous situation, resulting in fire or explosion that can cause damage, serious injury or death. Normal Part 2 Upon entry, the igniter is commanded off, the Flame Proven output is commanded on, and the Main Fuel Valve and Air Valve are commanded on. The Pilot (Low Fire) Valve remains on. The commanded Low Fire motor position is unchanged. This state will continue for five seconds. A flame failure will result in a lockout. A lockout will also occur if Fire input becomes de-energized during this state. Special function terminal 2 is ignored during this timed period. At the end of the timed period, the sequence will go back to the end of the Normal Part 1 state if special function 2 is de-energized. If special function 2 is energized and special function 4 is deenergized, a Hold will occur. If special function 4 is energized, the sequence will proceed to the Normal Part 3 state. Normal Part 3 All commanded outputs remain unchanged. The igniter is commanded off and Flame Proven output, Pilot (Low Fire Valve), Main Fuel Valve and Air Valve are commanded on. The sequence will lockout if the Limits Complete is de-energized or a flame failure occurs. The sequence will lockout if special function 2 is de-energized. and special function 4 is energized. If special functions 2 and 4 are energized, the motor position will be Modulated. If special function 2 is energized and special function 4 is de-energized, the commanded motor position will be the Low Fire position and an alarm will occur if the Low Fire input is de-energized after four minutes. If special functions 4 and 2 are both de-energized, an alarm will occur if the Low Fire input is de-energized anytime after four minutes and a lockout will occur after a total of eight minutes has elapsed. If special functions 2 and 4 are de-energized, the sequence will return to the end of the Normal Part 1 state when the Low Fire input is energized (after a two- to threesecond Debounce period). Otherwise, the Normal Part 3 state will proceed to Standby when special function 1 becomes de-energized. For High/Low Stepfire and Off/On Stepfire sequences, Fire input (Low Fire switch) is not used but must be jumpered to prevent a Hold condition in Standby. High/Low Stepfire Part 1 High/Low Stepfire Part 1 is entered only from the Standby state with Limits Complete Fire inputs energized and special function 1 energized. Upon entry to this state, the Igniter and the Pilot (Low Fire Valve) are commanded on, and the motor position is commanded to Low Fire. The Main Valve, Air Valve and Flame Proven outputs are commanded off. HIGH/LOW STEPFIRE PART 1 LASTS FOR FOUR SECONDS. Fire input is ignored during this state, and special functions 2, 3 and 4 are ignored. If, at the end of the timed period, the flame has not been established, a lockout will occur. Otherwise, with flame established, the High/ Low Stepfire Part 2 is entered. High/Low Stepfire Part 2 Upon entry to this state, the Pilot (Low Fire) Valve is commanded on, the Igniter and Main Valve are commanded off, the Flame Proven output is commanded on, the commanded motor position is Low Fire and a two-second timer is started. A lockout will occur if a flame failure occurs. Special functions 3 and 4 are ignored. The High state will be entered if special function 2 is energized and the two-second timer has expired. Otherwise, High/Low Stepfire Part 2 continues. Fire input is ignored during this state. High State Upon entry to High State, the Main and Air Valves are commanded on, and the Pilot (Low Fire Valve) and Flame Proven outputs are commanded on. A two-second timer is started. The commanded motor position is changed from Low Fire to Modulate. A lockout will occur if a flame failure occurs. Fire input and special functions 3 and 4 are ignored

25 The High/Low Stepfire Part 2 state will be re-entered if special function 2 is de-energized and the two-second time has expired. Otherwise, High State will continue until special function 1 is de-energized, causing entry to Standby. Off/On Stepfire Part 1 Off/On Stepfire Part 1 is entered only from the Standby state, with Limits Fire and special function 1 energized. When Off/On Stepfire Part 1 is entered, the igniter, Pilot (Low Fire Valve) and Air Valve are commanded on, while the Main Valve and Flame Proven are commanded off. The commanded motor position is Modulate. Part 1 lasts for four seconds. The flame signal Fire inputs are ignored during this state while a Pilot/Low Fire (flame) is being established. The sequence will lockout if Limits Complete becomes deenergized. Special functions 2, 3 and 4 are ignored. At the end of the time period, if the flame has not been established, a lockout will occur. Otherwise, with the flame established, Off/ On Stepfire Part 2 is entered. Off/On Stepfire Part 2 When On/Off Stepfire Part 2 is entered, the igniter is commanded off and the Pilot (Low Fire) Valve, Main Valve and Flame Proven are commanded on. The commanded motor position remains at modulate. Special functions 2, 3 and 4 are ignored. The RM7888A will lockout if a flame failure occurs. Fire input is ignored during this state. The sequence will lockout if the Limits Complete becomes deenergized. Off/On Stepfire Part 2 proceeds to Standby if special function 1 becomes de-energized. Lockout Lockout is entered when a timed sequence hold expires or a signal is not in the required state. The RM7888A DSI configuration sequence description details the conditions under which the sequence will lockout. Figs. 21 through 23 show the timing relationship between the RM7888A inputs and outputs for each sequence state during DSI Normal, DSI High/Low Stepfire and DSI Off/On Stepfire sequences. INPUT & OUTPUT SIGNALS MAIN ALARM STANDBY STANDBY- PURGE NORMAL- PART 1* POSSIBLE INFINITE HOLD NORMAL- PART 2 5 SECONDS, POSSIBLE INFINITE HOLD MAIN NORMAL- PART 3 0 TO INFINITE SECONDS MAIN IGNITION- T10 - T8 MAIN- T9 AIR VALVE- T5 PROVEN- T21 ALARM- T3 MOTOR POSITION- T12-T15 L/H/MOD L L MOD OR LOW FIRE INPUT- T18 LIMITS COMPLETE- T7 SF1 SPECIAL FUNCTION- T6 TO STANDBY SF2 SPECIAL FUNCTION- T17 TO END OF PART 1 SF3 SPECIAL FUNCTION- T19 SF4 SPECIAL FUNCTION- T20 SENSED *RM7888A1001 AND A1019 ARE 4 SECONDS. RM7888A1027 IS 10 SECONDS. M9498B Fig. 21. DSI Normal sequence timing diagram

26 INPUT & OUTPUT SIGNALS MAIN STANDBY STANDBY- PURGE HIGH/LOW STEPFIRE- PART 1* HIGH/LOW STEPFIRE- PART 2 2 TO INFINITE SECONDS HIGH 2 TO INFINITE SECONDS MAIN RETURN TO HIGH/LOW STEPFIRE- PART 2 ALARM IGNITION- T10 (SEE PREVIOUS COLUMN FOR PART 2) - T8 MAIN- T9 AIR VALVE- T5 PROVEN- T21 ALARM- T3 MOTOR POSITION- T12-T15 L/H/MOD L L LOW FIRE INPUT- T18 LIMITS COMPLETE- T7 SF1 SPECIAL FUNCTION- T6 SF2 SPECIAL FUNCTION- T17 SF3 SPECIAL FUNCTION- T19 SF4 SPECIAL FUNCTION- T20 SENSED *RM7888A1001 AND A1019 ARE 4 SECONDS. RM7888A1027 IS 10 SECONDS. M9499B Fig. 22. DSI High/Low Stepfire sequence timing diagram

27 INPUT & OUTPUT SIGNALS MAIN STANDBY STANDBY- PURGE OFF/ON STEPFIRE- PART 1* OFF/ON STEPFIRE- PART 2 5 TO INFINITE SECONDS MAIN ALARM IGNITION- T10 - T8 MAIN- T9 AIR VALVE- T5 PROVEN- T21 ALARM- T3 MOTOR POSITION- T12-T15 L/H/MOD MOD LOW FIRE INPUT- T18 LIMITS COMPLETE- T7 SF1 SPECIAL FUNCTION- T6 TO STANDBY SF2 SPECIAL FUNCTION- T17 SF3 SPECIAL FUNCTION- T19 SF4 SPECIAL FUNCTION- T20 SENSED *RM7888A1001 AND A1019 ARE 4 SECONDS. RM7888A1027 IS 10 SECONDS. M9492B Fig. 23. DSI On/Off Stepfire sequence diagram. STATIC CHECKOUT CAUTION 1. Use extreme care while testing the system. Line voltage is present on most terminal connections when power is on. 2. Open the master switch before installing or removing a jumper on the subbase. 3. Before continuing to the next test, be sure to remove the test jumper(s) used in the previous tests. 4. Replace all limits and interlocks not operating properly. Do not bypass limits and interlocks. 5. Close all manual fuel shutoff valve(s) before starting these tests. After checking all wiring, perform this checkout before installing the RM7888A on the subbase. These tests verifies that the Q7800 Wiring Subbase is wired correctly, and that the external controllers, limits, interlocks, actuators, valves, transformers, motors and other devices are operating properly. Do not perform a dielectric test with the RM7888A installed. Internal surge protectors will break down and conduct a current. This could cause the RM7888A to fail the dielectric test or possibly destroy the internal lightning and high current protection

28 Equipment Recomended Voltmeter 1Mohm/volt minimum sensitivity set on the Vac scale. Two jumper wires; 14 AWG wire, insulated, 12 inches (304.8 mm) long, with insulated alligator clips at both ends. An ammeter can replace one jumper wire so the current draw of the loads (pilot valve, main valve and ignition transformer) can be checked. General Instructions 1. Perform all applicable tests listed in Static Checkout, Table 10, in the order listed. 2. Make sure that all manual fuel shutoff valve(s) are closed. 3. For each test, open the master switch and install the jumper wire(s) between the subbase wiring terminals listed in the Test Jumpers column. 4. Close the master switch before observing operation. 5. Read the voltage between the subbase wiring terminals listed in the Voltmeter column. 6. If there is no voltage or the operation is abnormal, check the circuits and external devices as described in the last column. 7. Check all wiring for correct connections, tight terminal screws, correct wire, and proper wiring techniques. Replace all damaged or incorrectly sized wires. 8. Replace faulty controllers, limits, interlocks, actuators, valves, transformers, motors and other devices as required. 9. Obtain normal operation for each required test before continuing the checkout. 10. After completing each test, be sure to remove the test jumper(s). Test No. Table 10. Static Checkout. Test Jumpers Voltmeter Normal Operation If Operation Is Abnormal, Check The Items Listed Below WARNING Make sure all manual fuel shutoff valves are closed. IMPORTANT Low fuel pressure limits, if used, could be open. Bypass them with jumpers for the remaining Static Tests (if required). 1 None 4-L2 Line voltage at terminal Master switch. 2. Power connected to the master switch. 3. Overload protection (fuse, circuit breaker) has not opened the power line. 2 None 7-L2 Line voltage at terminal Limits Air Valve starts. 1. Air Valve circuit. a. Manual switch of Air Valve. b. Air Valve power supply, overload protection, and starter. c. Air Valve Ignition spark 1. Watch for spark or listen for buzz. a. Ignition electrodes are clean. b. Ignition transformer Automatic pilot valve opens. Refer to wiring diagram of system being tested. 1. Listen for click or feel head of valve for activation. a. Actuator if used. b. Pilot valve Automatic main fuel valve(s) opens. 1. Listen for and observe operation of the main fuel valve(s) and actuator(s). 2. Valve(s) and actuator(s) Alarm (if used) turns on. 1. Alarm and and L2 Firing rate motor drives open; zero volts at terminal 18 after motor starts driving open. 18-L2 Firing rate motor drives closed; line voltage at terminal 18 after motor is in Low Fire position. WARNING Make sure all manual fuel shutoff valves are closed. 1. Low Fire Start Switch. 2. Firing rate motor and transformer. 1. Low Fire Start Switch. 2. Firing rate motor and transformer

29 Test No. Table 10. Static Checkout. (Continued) Test Jumpers Voltmeter Normal Operation If modulation is used, raise setpoint of series 90 controller firing rate motor should drive toward open. 2. Lower set point of series 90 controller firing rate motor should drive toward closed. If Operation Is Abnormal, Check The Items Listed Below 1. Series 90 Controller. 2. Firing rate motor and transformer Flame Proven circuit. * Apply 120 Vac power to the special function inputs from the external controller/device one at a time (in sequence) and perform tests 12 through L2 1. Special Function 1 circuit , 19, 20-L L2 1. Special Function 2 circuit. 2. 6, 19, 20-L L2 1. Special Function 3 circuit. 2. 6, 17, 20-L L2 1. Special Function 4 circuit. 1. 6, 17, 19-L2 Final CAUTION On completing these tests, open the master switch and remove all test jumpers from the subbase terminals. Also remove bypass jumpers from the low fuel pressure limits (if used). CHECKOUT WARNING Do not allow fuel to accumulate in the combustion chamber. If fuel is allowed to enter the chamber for longer than a few seconds without igniting, an explosive mixture could result. It is recommended that the trial for pilot be limited to ten seconds, and the attempt to light the main burner be limited to two seconds from the time the fuel has reached the burner nozzle. In any case, do not exceed the nominal lightoff time specified by the equipment manufacturer. Close the manual fuel shutoff valve(s) if the flame is not burning at the end of the specified time. CAUTION If an RM7888A is replaced with a lower functioning 7800 SERIES Relay Module, the burner will not sequence unless wiring changes are made. IMPORTANT 1. If the system fails to perform properly, refer to the Troubleshooting section and 7800 SERIES System Annunciation and Troubleshooting, form Repeat ALL required Checkout tests after all adjustments are made. ALL tests must be satisfied with the flame detector(s) in its FINAL position. Equipment Recommended Volt-ohmmeter (1 Megohm/volt minimum sensitivity) with: CAUTION 1. Use extreme care while testing the system. Line voltage is present on most terminal connections when power is on. 2. Open the master switch before removing or installing the RM7888A. 3. Make sure all manual fuel shutoff valve(s) are closed before starting the initial lightoff check and the Pilot Turndown tests. 4. Do not put the system in service until you have satisfactorily completed all applicable tests in this section and any others required by the equipment manufacturer Vac capability ohm capability Vdc capability. Checkout Summary Ignition spark pickup all installations using Ultraviolet Flame Detectors. Preliminary inspection all installations. Flame signal measurement all installations. Initial lightoff check for proved pilot all installations using a pilot. Initial lightoff check for direct spark ignition of oil all burners using DSI. Pilot turndown test all installations using a pilot. Hot refractory saturation test all installations using Infrared (lead sulfide) Flame Detectors. Hot refractory hold-in test all installations. Ignition interference test all installations using flame rods

30 Response to other ultraviolet sources all installations using Ultraviolet Flame Detectors. Flame signal with hot combustion chamber all installations. Safety shutdown tests all installations. See Figs. 9 and 10 or Q7800 Specifications for terminal locations. 9. System is in the Standby condition. LED is energized. 10. All limits and interlocks are reset. Flame Signal Measurement (Table 11 and Fig. 24) Preliminary Inspection Perform the following inspections to avoid common problems. Make certain that: NEGATIVE ( ) METER LEAD POSITIVE (+) METER LEAD ONE MEGOHM/VOLT METER 1. Wiring connections are correct and all terminal screws are tight. 2. Flame detector(s) is clean, installed and positioned properly. Consult the applicable Instructions. 3. Correct combination of amplifier and flame detector(s) is used. See Table 4 in the Specifications section. 4. Plug-in amplifier is securely in place. 5. Burner is completely installed and ready to fire; consult equipment manufacturer instructions. Fuel lines are purged of air. 6. Combustion chamber and flues are clear of fuel and fuel vapor. 7. Power is connected to the system disconnect switch (master switch). 8. Lockout is reset (push in reset button), only if the RM7888A is powered. Fig. 24. Flame signal measurement. M7382A Table 11. Flame Signal. Flame Detector Signal Amplifier Minimum Acceptable Steady dc Voltage a Maximum Expected dc Voltage Flame Rod C7012A,C R7847A,B c 1.25 Vdc 5.0 Vdc at Keyboard Display Module or 5.0 Vdc at a 1 Megohm/volt meter C7012E,F R7847C b C7915A R7852A,B c C7027A R7849A,B c C7035A C7044A C7061 R7861 C7076A,D R7886A C7961 R7851C C7927, C7961 R7851B c a This minimum or stronger signal should be obtained easily if the detector is correctly installed and positioned to properly sense the flame. This voltage must be obtained before completing checkout. b The flame signal amplifier circuitry is tested one-half second every five seconds during burner operation and shuts down the burner if the amplifier fails (all installations). c The flame amplifier is an Ampli-Check type. Measure the flame signal at the appropriate times defined in the following checkout tests. Read the flame signal in volts dc at the flame amplifier test jacks + and -(Com). 1. Use a 1 Megohm/volt meter with a 0 to 10 Vdc capability. 2. Set the 1 Megohm/volt meter to the 0 to 10 Vdc range. 3. Insert the positive (red) probe into the + jack of the flame amplifier. Insert the negative (black) probe into the - (Com) jack of the flame amplifier (see Fig. 24). 4. Allow a few seconds for the meter reading to stabilize. 5. If using AMPLI-CHECK or shutter check amplifiers, read the average stable voltage, disregarding the peaks caused by the self-checking operation. 6. The meter reading must be as specified in Table 11 after all tests are completed and all adjustments made